Duct-making machine

ABSTRACT

Duct-making machine comprises, from its feed to its discharge, and first top sheet forming then bottom sheet forming, top sheet feed and rigidizing rolls, flange rolls, right-angle bend rollers, bottom sheet feed and rigidizing rolls, crimping rollers, and staking rollers. The respective feed and rigidizing rolls are operable to draw sheet stock from supply rolls mounted on commonly known decoilers, and may include complementary hard and soft roll bodies.

United States Patent [191 Priest 51 Aug. 26, 1975 1 DUCT-MAKING MACHINE[76] Inventor: Rod M. Priest, 1033 W, Amity Rd.,

Boise, Idaho 83705 [22] Filed: Feb. 28, 1974 [21] Appl. No.: 446,876

[52] US. Cl 113/54; 72/52 [51] Int. Cl B2ld 39/02 [58] Field of Search113/54, 55; 72/DIG. 14,

[56] References Cited UNITED STATES PATENTS 2,637,365 5/1953 Stockton72/D1G. 14 3,636,903 1/1972 Anderson ct all 113/54 Thompson 1 13/553,797,430 3/1974 Boudreau 113/55 Primary ExamirzerRichard J HerbstAttorney, Agent, or Firm-John W. Kraft; Charles L.

Kraft [5 7 ABSTRACT Duct-making machine comprises, from its feed to itsdischarge, and first top sheet forming then bottom sheet forming, topsheet feed and rigidizing rolls,

flange rolls, right-angle bend rollers, bottom sheet feed and rigidizingrolls, crimping rollers, and staking rollers. The respective feed andrigidizing rolls are operable to draw sheet stock from supply rollsmounted on commonly known decoilers, and may include complementary hardand soft roll bodies.

6 Claims, 10 Drawing Figures PATENTEBAUEZBIQYS 3 901 174 SHEET 1 BF 3PATENTEI] AUBZ 6 I975 SELU 2 UP 3 FIG. 5

FIG. 7

DUCT-MAKING MACHINE FIELD OF INVENTION The present invention relates .tosheet-metaldeforming apparatus, and more particularly to an apparatusfor forming and seaming separate sheet stock elements into products suchas duct.

BACKGROUND OF THE INVENTION It is a primary object of this invention toprovide apparatus for mechanically forming and seaming separate sheetstock'elements into products such as duct.

It is another object of this invention that there be provided means forrigidizing the aforesaid sheet stock elements.

It is further primary object of this invention that the seams formed bythe present apparatus be crimped or staked, resulting in a sealed seam.

It is an object of this invention that the seams formed by means of thepresent apparatus be juxtapositioned to provide at least part of themounting flange for the product.

It is a further primary object that this invention be not onlymechanical and automatic in its forming and seaming functions, but thatit be structurally and mechanically simplified over apparatus of theprior art.

These and other objects shall become apparent from the descriptionfollowing, it being understood that modifications may be made withoutaffecting the teachings of the invention here set out.

SUMMARY OF THE INVENTION Duct-making machine comprises, from its feed toits discharge, and first top sheet forming then bottom sheet forming,top sheet feed and rigidizing rolls, flange rolls, right-angle bendrollers, bottom sheet feed and rigidizing rolls, crimping rollers, andstaking rollers. The respective feed and rigidizing rolls are operableto draw sheet stock from supply rolls mounted on commonly knowndecoilers, and may include complementary hard and soft roll bodies.

A more thorough and comprehensive understanding may be had from thedetailed description of the preferred embodiment when read in connectionwith the drawings forming a part of this specification.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a-side elevational view ofthe duct-making apparatus of this invention including sheet supply rollsand a block and shear associated therewith.

FIG. 2 is a top plan of the duct-making machine shown with the housingthereof removed.

FIG. 3 is a side elevational view of the apparatus of the FIG. 2.

FIG. 4 is a cross-sectional view taken substantially along the lines 4-4of the FIG. 3 of the top sheet feed and rigidizing rolls shown withportions broken away to show the interior configuration thereof.

FIG. 5 is a cross-sectional view taken substantially along the lines 55of the FIG. 3 showing the flange rolls.

FIG. 6 is a cross-sectional view taken substantially along the lines 6-6of the FIG. 3 showing the bottom sheet feed and rigidizing rolls.

FIG. 7 is a cross-sectional view taken substantially along the lines 7-7of the FIG. 2 showing a typical flange guide roller.

FIG. 8 is a cross-sectional view taken substantially along the lines 8-8of the FIG. 2 showing a typical staking roller.

FIG. 9 is a cross-sectional detail of a typical seam formed by thepresent machine.

FIG. 10 is a fragmentary perspective view of a section of completed ductfabricated by the present ductmaking machine.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now to thedrawings and more particularly to the FIGS. 1, 2 and 3, the duct-makingmachine of this invention is shown to advantage and generally identifiedby the numeral 10. As shown in the FIG. 1, the duct machine 10 isassociated with a pair of superimposed supply rolls of sheet material 1l and 12 which are detachably mounted on a decoiler frame 13. The rolls11 and 12 may be loaded to release sheet substantially parallel betweentheir centers. Thus, the top roll 11 feeds from its lowermost side, andthe bottom roll 12 feeds from its uppermost side. The duct machine 10may be associated at its discharging end with a block and shear 14 whichcuts the fabricated duct 10' to length. The block and shear 14 may beeither manually or mechanically operated.

Referring to the FIGS. 2 and 3, the duct-making machine 10 comprises aframe 10" and, from its feed to its discharge, top sheet feed andrigidizing rolls l5 and 16, flange rolls 17 and 17', bottom sheet feedand rigidizing rolls 20 and 21, flange guide rollers 22 and 22' andstaking rollers 23 and 23'. The duct-making machine 10 may be driven byany of a number of arrangements of transmissions 24 and chain drive 24'and a motor at 24", such as shown in FIG. 3.

Referring now to the FIG. 4, the feed and rigidizing rollers 15 and 16are operable to draw sheet stock 11 from the rolls 1 1. As shown inconnection with FIG. 10, the rolls 15 and 16 also form a plurality ofrectilinear ridges 25 in the top sheet 11', a plurality of transversestiffening ridges 26, and flanges 27 disposed along the terminal edgesof the sheet stock 11. As shown in the FIG. 10, the ridges 25 and 26 areintended as stiffening means for the top wall and side wallrespectively, of a completed duct 10'. The rectilinear ridges 25 areformed by die rings 29 disposed at suitable intervals on the cylindricalbody of the upper male roll 15. Break rings 30 are provided distally ateach end of the roll 15 to score the top sheet 11 along the lines of therightangle bends, forming side walls of the duct 10', as shall bedescribed hereinafter. The rings 29 project transversely at intervalsalong the cylindrical body of the rolls 15. The transverse ridges 26 areformed by blades 31 which project rectilinearly at intervals over thesurface of the cylindrical body of the roll 15. As shown in FIG. 3, itmay be seen that the distance between the ridges 26 is determined by thecircumferential distance between the blades 31. The cylindrical body ofthe roll 15 is carried on a shaft 32 which is journally mounted andsuitably driven. The female roll 16 is suitably mounted and driven insuperimposed fashion under the roll 15, and includes a hard resilientcylindrical body 33 which is carried on a shaft 34. Each of the flanges27 are formed by two draws in a sequence by passing sheet 11' throughthe rolls 15 and 16 and then through the rolls 17 and 17. It has beenfound that by treating the top sheet stock 11' in two draws, wrinklesand breakage in the material may avoided. Accordingly, the ends of themale roll 15 are provided with relatively shallow concave die rings 35which have asymmetrical angular configuration to initiate the firstdraw. The female roll 16 includes complementary convex rings 36 operableto receive therings 35. r Referring to the FIG. 5, the second draw toform the flange 27 is achieved by passing the sheet '11 through therolls 17 and 17. The rolls l7 and 17 each include a suitably mounteddriven shaft 37 and 38 respectively, each having rubber feed wheels 39and 39' to drive the sheet 11 through the machine 10, and complementarydie wheels 40 and 41, respectively. As above with the rolls l and 16,the upper roll 17 carries a concave flanging wheel 40 and the lower rollcarries a complementary convex die wheel 41. It may be seen that,between the dies 35 and 36 and between the dies 40 and 41, the latter isconfigured a sharper and deeper relief than the former. It may be seenthat in certain applications the duct-making machine may be so adaptedto form a flange 27 by a single set of flanging dies 35 and 36'. I I

Referring to the FIG. 3 the flange guide rollers 22 and 22"are mountedat the discharge end of a guide bed 42, which controls the travel of thesheets 11 and 12. A C-channel track 43 is disposed at each side of theintended travel of the lower sheet 12 over the entire length of themachine 10 to the flange guide rollers 22 and 22'. The top sheet 11 isfirst carried by the rolls and 16, and 17 and 17' as set out above.Journalled rollers 42' at each side of the travel of the top sheet stock11', guide and form top and side walls of a completed duct 10. The topsheet stock 11' is also guided by a plurality of cornering rollers 42',located above and below generally at the discharge end of the guide 42,and bars 42", located at each side of the intended lateral travel,further the bending of the duct walls. Idling rollers 44 may be locatedat points at which the sheets 11 and 12 begin to sag or changedirection. The distance between the rolls 17 and 17', and the rollers 22and22 is generally determined by the length required by the sheet stock1 l to roll over the side walls without tearing or wrinkling. It may beseen that the guide lips 45 may be provided to cover the entire width ofthe sheet stock 11 and 12 at the head of these guide areas to facilitatefeeding to the various rolls and rollers.

7 Referring again to the FIGS. 2, 3 and 6, the bottom sheet feed andrigidizing rolls and 21 are operable to draw rectilinear ridges 46 and aplurality of transverse ridges 46'. As shown in the FIG. 10, the bottomsheet 12 is a suitably stiffened, flat member locked within the flanges27 formed by the rollers 15 and 16, and 17 and 17. Accordingly, the feedand rigidizing rollers 20 and 21 are provided with means for forming thestiffing ridges 46 and 46 in similar juxtaposition to the rollers 15 and16. The upper roll 20 is carried on a shaft 20 and provided with a pairof die rings 47 which project transversely and distally from each sideof the midpoint of the cylindrical roll body of the roll 20, and withrectilinearly projecting blades 48 issuing from between the rings 47,and between the rings 47 and the terminal ends of the body. The lowerfemale roll 21 includes a hard resilient cylindrical body 49 mounted ona shaft 50. The nib of the rolls 20 and 21 is aligned with the guidechannel43 forward along the line of travel from the rolls l7 and 17'. Asset out above, the rolls 20 and 21 are suitably joumally mounted anddriven to insure suitable feeding of the sheet stock 12' in relation tothe stock 11.

Referring again to FIGS. 2, 3 and 7, the flange guides 22 and 22 aremounted distally along the line of travel between the end of the guidebed 42 and the staking rollers 23 and 23'. A groove 22" in thecircumferential face of the roller 22 finally brings the flanges 27about the edge of the bottom sheet 12. The rollers 22 and 22' aremounted with their circumferential faces parallel to the predetermineddimension of the lower edges of side walls formed from the top sheet11'.

Referring again to the FIGS. 2 and 3, the staking rollers 23 and 23' arejournally mounted distally forward along the line of travel from therollers 22 and 22', and are operable to form a detented locking seam inthe flanges 27. As shown in FIG. 8, the staking rollers 23 and 23 areprovided with upper rollers 23 having a plurality of projectinggear-like punches 52 disposed about its circumferential face. The lower,complementary roller 23' is provided with a multiplicity of recesses 53operable to receive the punch 52. It may be seen that the lower roller23', like the female rolls 16 and 21, may be provided with a hardresilient body and recesses 53.

Referring to the FIGS. 2 and 3, and 9 and 14), top sheet stock 11 may befed with the bottom sheet stock 12' into the duct-making machine 10. Itmay be seen that the width of the sheet stock 11 should be sufficient toform the side walls and the upper wall of duct 10 while the bottom sheetstock 12' forms the bottom wall of duct 10. The top sheet stock 11 isrigidized and flanged by the set of rollers 15 and 16, and 17 and 17 asset out above. The top sheet stock 11 is then formed into asquare-cornered, inverted U-shaped trough by means of the guide bed 42,the bars 42 the rollers 22 and 22' and the cornering rollers 42. Thebottom sheet stock 12 is rigidized and fed by the rollers 20 and 21 andcomes into registry with the flanges 27 of the now troughed top sheetstock 12' at the crimping rollers 22 and 22. The staking rollers 23 and23' then collate the flanges 27 about the terminal edges of the bottomsheet stock 11'.

As shown more clearly in the FIG. 9, the staking rollers 23 and 23 alsoform a detented locking seam 27' in the crimp flanges 27 by means of thepunches 52 and recesses 53. As set out above and as shown in FIG. 1, theblock and shear 14 may be employed to cut completed duct 10' to length.

Having thus described in detail a preferred apparatus which embodies theconcepts and principles of the invention and which accomplishes thevarious objects, purposes and aims thereof, it is to be appreciated andwill be apparent to those skilled in the art that many physical changescould be made in the apparatus without altering the inventive conceptsand principles embodied therein. Hence, it is intended that the scope ofthe invention be limited only to the extent indicated in the appendedclaims.

I claim:

1. A machine for forming duct from sheet stock, comprisiing; from itsfeed to its discharge, and first from means forming a top sheet and thenmeans forming a bottom sheet wherein said top sheet is sufficiently wideto form the top and side walls of a duct and wherein said bottom sheetis sufficiently wide to form the bottom wall thereof:

top sheet feed and rigidi'zing rolls including a male roll having a diering which projects at each terminal end of said roll, and a pair of dierings distally from each of the terminal ends of said male roll forminga crease in said top sheet demarcating said top wall and said side wallsof said duct, and female roll suitably mounted and driven superimposedfashion in said male roll and having at each of its terminal ends aconcave die wheel each of which is in registry and mates with saidprojecting die ring at each of the terminal ends of said male roll, andwherein the body of said female roll is operable to receive said dierings disposed distally from the terminal ends of said male roll;

flange rolls suitably mounted and driven in superimposed fashion andincluding flanging male and female die wheels mounted at the terminalend of said flange roll in registry with the die rings and wheelsmounted at the terminal ends of said top sheet and rigidizing rolls, andidling means for engaging said top sheet for feeding thereof;

a flange guide having means to guide and bend said side wallssubstantially perpendicular to the top wall demarcated by said top feedand rigidizing rolls;

a bottom sheet feed and rigidizing roll being suitably mounted anddriven having a male roll superimposed over a female roll;

staking rollers including a pair of superimposed rollers journallymounted at each side of said machine in registry with said flangesmating to crimp said flanges about the terminal edges of said bottomsheet, and having gear-like punches disposed about the circumferentialfaces of one of said superimposed rollers and a complementary rollerprovided with a multiplicity of recesses for receiving said punches thusforming a detented seam at said flanges; and

flange guide rollers being mounted with their circumferential facesdisposed parallelly at the intended dimension of the lower edges of saidside walls, and having a groove in their circumferential stages forcollating said flanges about the terminal edges of said bottom sheet 2.The apparatus of claim 1 wherein said feed and rigidizing rollersinclude a plurality of projecting rings disposed about thecircumferential edges of the respective male rolls and a plurality ofrectilinear disposed blades along said cylindrical wall, and wherein therespective female rolls have means for receiving said rings and blades.

3. The apparatus of claim 2 wherein said means for receiving said ringsand blades are recesses.

4. The apparatus of claim 2 wherein said means for receiving said ringsand blades is a resilient body on said female rolls.

5. The apparatus of claim 1 wherein said means against whichsaidright-angle bend rollers acts is a convoluted table-like servicehaving a guide rip at each of its terminal sides.

6. The apparatus of claim 1 wherein said means for controlling saidsheet'stock includes a plurality of rubber wheels mountedo'n the rollshafts.

1. A machine for forming duct from sheet stock, comprisiing; from itsfeed to its discharge, and first from means forming a top sheet and thenmeans forming a bottom sheet wherein said top sheet is sufficiently wideto form the top and side walls of a duct and wherein said bottom sheetis sufficiently wide to form the bottom wall thereof: top sheet feed andrigidizing rolls including a male roll having a die ring which projectsat each terminal end of said roll, and a pair of die rings distally fromeach of the terminal ends of said male roll forming a crease in said topsheet demarcating said top wall and said side walls of said duct, andfemale roll suitably mounted and driven superimposed fashion in saidmale roll and having at each of its terminal ends a concave die wheeleach of which is in registry and mates with said projecting die ring ateach of the terminal ends of said male roll, and wherein the body ofsaid female roll is operable to receive said die rings disposed distallyfrom the terminal ends of said male roll; flange rolls suitably mountedand driven in superimposed fashion and including flanging male andfemale die wheels mounted at the terminal end of said flange roll inregistry with the die rings and wheels mounted at the terminal ends ofsaid top sheet and rigidizing rolls, and idling means for engaging saidtop sheet for feeding thereof; a flange guide having means to guide andbend said side walls substantially perpendicular to the top walldemarcated by said top feed and rigidizing rolls; a bottom sheet feedand rigidizing roll being suitably mounted and driven having a male rollsuperimposed over a female roll; staking rollers including a pair ofsuperimposed rollers journally Mounted at each side of said machine inregistry with said flanges mating to crimp said flanges about theterminal edges of said bottom sheet, and having gear-like punchesdisposed about the circumferential faces of one of said superimposedrollers and a complementary roller provided with a multiplicity ofrecesses for receiving said punches thus forming a detented seam at saidflanges; and flange guide rollers being mounted with theircircumferential faces disposed parallelly at the intended dimension ofthe lower edges of said side walls, and having a groove in theircircumferential stages for collating said flanges about the terminaledges of said bottom sheet.
 2. The apparatus of claim 1 wherein saidfeed and rigidizing rollers include a plurality of projecting ringsdisposed about the circumferential edges of the respective male rollsand a plurality of rectilinear disposed blades along said cylindricalwall, and wherein the respective female rolls have means for receivingsaid rings and blades.
 3. The apparatus of claim 2 wherein said meansfor receiving said rings and blades are recesses.
 4. The apparatus ofclaim 2 wherein said means for receiving said rings and blades is aresilient body on said female rolls.
 5. The apparatus of claim 1 whereinsaid means against which said right-angle bend rollers acts is aconvoluted table-like service having a guide rip at each of its terminalsides.
 6. The apparatus of claim 1 wherein said means for controllingsaid sheet stock includes a plurality of rubber wheels mounted on theroll shafts.